Risk Assessment-Oriented Design of a Needle Insertion Robotic System for Non-Resectable Liver Tumors
Abstract
:1. Introduction
2. Materials and Methods
2.1. General Requirements
- The robotic system should be able to position the needle within a very tight space in the CT bore, above the patient’s abdominal cavity (functional requirement Func-01).
- 2.
- The robotic system should be able to provide a very accurate orientation of the needle inside the CT bore (functional requirement Func-02).
- 3.
- The robotic system should be able to position accurately the needles in a predetermined array (functional requirement Func-03).
- 4.
- The robotic system should be stiff enough to ensure a high precision (design requirement Des-01).
- 5.
- The robotic system should have a modular architecture for a broad variety of clinical applications (design requirement Des-02).
- 6.
- The needle insertion device should be sterilizable (design requirement Des-03).
- remove all electronics (including actuation motors) by designing it in such a way that it allows an easy connection/disconnection and removal.
- use sterilizable electronic equipment.
- 7.
- The robotic system should account for patient breathing (control requirement—Con-01).
- 8.
- The robotic system should account for the needle deflection (control requirement—Con-02).
- 9.
- Seamless integration within the clinical workflow (control requirement—Con-03).
2.2. The Solution
- Component 1 (A—CT scanner and B—external axis with 1 translational DoF)
- Component 2 (C—robotic system and D—MNID)
- Component 3 (E—stand and F—mobile platform that moves on a trajectory parallel with the moving table (couch) of the CT)
2.3. Risk Analysis
- Preplanning. Before performing the insertion procedure, based on an initial scan, a preplanning procedure is required, to define the safe needle insertion trajectories.
- Tumor’s registration. The patient, CT and the robotic system must run a registration procedure, where the position of the tumors is exactly defined within the robotic system coordinates. This is achieved using a set of metal markers (steel balls) fixed placed on the patient’s body.
- Needle trajectory definition. Based on the preplanning results and the final tumor’s position relative to the robotic system’s coordinates, each needle trajectory is defined.
- Needle insertion. The first needle in partially inserted up to a safe depth. A visual confirmation is required, using local CT scans, and thus, the needle trajectory is validated. In case the needle’s actual trajectory does not fit the predetermined one, the trajectory needs corrections. This means that the needle needs to be retracted and re-inserted using a new trajectory using the same target point into the tumor. If the needle trajectory is validated, another insertion depth is defined, and a second needle is taken from the needles rack and the entire procedure is repeated for each needle.
- Expected: 100;
- Quite possible: 80–99;
- Unusual, but possible: 50–79;
- Possible but unlikely: 30–49;
- Minor: 0–29.
- Catastrophic: 100;
- Critical: 80–99;
- Serious: 60–79;
- Moderate: 30–59;
- Negligible: 0–29.
- Critical >180;
- High: 150–179;
- Moderate: 120–149;
- Minor: 50–119;
- Negligible: 0–49.
2.4. Failure Mode and Effect Analysis of the MNID
- Identify the subsystems of the selected system (if the case);
- Analyze the main functions of the components;
- Identify the breakdown modes of each element performing the MNID functions, their potential effect, cause and the means to resolve the issues and avoid the negative results;
- Assess the identified hazards in terms of severity, occurrence and detection and calculate the Risk Priority Number (RPN = severity × occurrence × detection scores).
- I.
- IF Severity is H AND Occurrence is O AND Detection is M THEN RPN is H
- II.
- IF Severity is H AND Occurrence is O AND Detection is VP THEN RPN is M
- III.
- IF Severity is H AND Occurrence is L AND Detection is VP THEN RPN is M
- IV.
- IF Severity is C AND Occurrence is L AND Detection is P THEN RPN is H
- V.
- IF Severity is H AND Occurrence is VL AND Detection is P THEN RPN is H
- VI.
- IF Severity is H AND Occurrence is O AND Detection is VP THEN RPN is L
- VII.
- IF Severity is H AND Occurrence is O AND Detection is RP THEN RPN is VH
- VIII.
- IF Severity is H AND Occurrence is VL AND Detection is VP THEN RPN is M
- IX.
- IF Severity is M AND Occurrence is L AND Detection is RP THEN RPN is VH
- X.
- IF Severity is M AND Occurrence is L AND Detection is VP THEN RPN is L
- XI.
- IF Severity is L AND Occurrence is VL AND Detection is VP THEN RPN is L
- XII.
- IF Severity is L AND Occurrence is L AND Detection is RP THEN RPN is VH
- XIII.
- IF Severity is L AND Occurrence is L AND Detection is M THEN RPN is H
- XIV.
- IF Severity is L AND Occurrence is L AND Detection is P THEN RPN is M
- XV.
- IF Severity is L AND Occurrence is VL AND Detection is VP THEN RPN is L
- XVI.
- IF Severity is M AND Occurrence is L AND Detection is RP THEN RPN is VH
- XVII.
- IF Severity is M AND Occurrence is L AND Detection is M THEN RPN is VH
- XVIII.
- IF Severity is M AND Occurrence is L AND Detection is P THEN RPN is H
- XIX.
- IF Severity is M AND Occurrence is L AND Detection is VP THEN RPN is L
- XX.
- IF Severity is C AND Occurrence is L AND Detection is VP THEN RPN is M
- XXI.
- IF Severity is C AND Occurrence is L AND Detection is P THEN RPN is VH
- XXII.
- IF Severity is C AND Occurrence is L AND Detection is VP THEN RPN is M
- XXIII.
- IF Severity is C AND Occurrence is VL AND Detection is P THEN RPN is H
- XXIV.
- IF Severity is C AND Occurrence is L AND Detection is RP THEN RPN is VH
- XXV.
- IF Severity is L AND Occurrence is O AND Detection is VP THEN RPN is L
- XXVI.
- IF Severity is H AND Occurrence is O AND Detection is P THEN RPN is H
- XXVII.
- IF Severity is M AND Occurrence is VL AND Detection is RP THEN RPN is VH
- XXVIII.
- IF Severity is H AND Occurrence is U AND Detection is VP THEN RPN is M
- XXIX.
- IF Severity is H AND Occurrence is U AND Detection is VP THEN RPN is M
- XXX.
- IF Severity is H AND Occurrence is O AND Detection is RP THEN RPN is H
3. Results
3.1. The Robotic System Design
3.2. The Control System
- User level, consisting of the KUKA smartPAD and the User Interface (PC);
- Control level, consisting of the KUKA Sunrise Cabinet and the PLC. The drivers used for the Nanotec stepper motors are also from B&R Automation, namely 80SD100XD.C011-01, each one being able to drive 2 motors;
- Physical level, consisting of the KUKA iiwa robot, the MNID and the 1 DoF axis, their actuators, and the sensory system. The latter consists of the proximity sensors used for the initialization procedure of each motion axis (and as stroke limiters) and the distance sensor from IFM.
3.3. Validation Tests
4. Discussion
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Hazard | En1 | En2 | En3 | En4 | En5 | En6 | En7 | En8 | MD1 | MD2 | Mean Value |
---|---|---|---|---|---|---|---|---|---|---|---|
M1 | 90 | 95 | 90 | 95 | 85 | 90 | 95 | 90 | 90 | 90 | 91 |
M2 | 70 | 80 | 90 | 80 | 75 | 65 | 70 | 75 | 65 | 70 | 74 |
M3 | 65 | 80 | 90 | 80 | 75 | 65 | 70 | 75 | 65 | 70 | 73.5 |
M4 | 85 | 85 | 90 | 85 | 90 | 95 | 75 | 80 | 70 | 75 | 83 |
M5 | 90 | 85 | 95 | 80 | 95 | 90 | 80 | 85 | 88 | 92 | 88 |
M6 | 70 | 75 | 60 | 65 | 60 | 70 | 80 | 75 | 70 | 70 | 69.5 |
E1 | 50 | 60 | 60 | 70 | 75 | 50 | 55 | 65 | 50 | 50 | 58.5 |
E2 | 50 | 60 | 65 | 55 | 58 | 65 | 70 | 75 | 55 | 60 | 61.3 |
E3 | 40 | 45 | 40 | 50 | 40 | 45 | 60 | 55 | 40 | 40 | 45.5 |
T1 | 45 | 35 | 40 | 45 | 55 | 45 | 50 | 55 | 35 | 40 | 44.5 |
I1 | 100 | 100 | 95 | 100 | 95 | 90 | 95 | 100 | 100 | 100 | 97.5 |
V1 | 50 | 55 | 60 | 45 | 50 | 65 | 40 | 35 | 40 | 40 | 48 |
V2 | 35 | 30 | 40 | 30 | 35 | 30 | 40 | 35 | 30 | 30 | 33.5 |
ER1 | 30 | 40 | 45 | 40 | 45 | 30 | 35 | 40 | 35 | 35 | 37.5 |
Hazard | En1 | En2 | En3 | En4 | En5 | En6 | En7 | En8 | MD1 | MD2 | Mean Value |
---|---|---|---|---|---|---|---|---|---|---|---|
M1 | 90 | 95 | 85 | 90 | 80 | 85 | 80 | 90 | 95 | 95 | 88.5 |
M2 | 85 | 85 | 90 | 85 | 80 | 90 | 80 | 75 | 75 | 75 | 82 |
M3 | 85 | 85 | 90 | 85 | 80 | 90 | 80 | 75 | 75 | 75 | 82 |
M4 | 100 | 100 | 100 | 100 | 100 | 95 | 100 | 100 | 100 | 100 | 99.5 |
M5 | 100 | 95 | 100 | 95 | 100 | 90 | 100 | 95 | 95 | 95 | 96.5 |
M6 | 80 | 85 | 75 | 70 | 85 | 70 | 65 | 75 | 75 | 70 | 75 |
E1 | 80 | 85 | 80 | 70 | 75 | 70 | 65 | 70 | 75 | 70 | 74 |
E2 | 100 | 95 | 100 | 90 | 95 | 100 | 95 | 90 | 95 | 100 | 96 |
E3 | 75 | 70 | 75 | 70 | 85 | 80 | 80 | 75 | 70 | 65 | 74.5 |
T1 | 60 | 55 | 50 | 55 | 55 | 50 | 60 | 55 | 55 | 50 | 54.5 |
I1 | 70 | 75 | 70 | 80 | 80 | 85 | 70 | 70 | 65 | 70 | 73.5 |
V1 | 80 | 85 | 80 | 90 | 85 | 70 | 80 | 85 | 70 | 65 | 79 |
V2 | 50 | 45 | 45 | 40 | 50 | 55 | 40 | 45 | 40 | 40 | 45 |
ER1 | 90 | 95 | 80 | 95 | 85 | 75 | 85 | 80 | 80 | 80 | 84.5 |
Hazard | Score | Evaluation |
---|---|---|
M1 | 179.5 | High |
M2 | 156 | High |
M3 | 155.5 | High |
M4 | 169.5 | High |
M5 | 178.5 | High |
M6 | 144.5 | Moderate |
E1 | 132.5 | Moderate |
E2 | 146.3 | Moderate |
E3 | 119.5 | Minor |
T1 | 99 | Minor |
I1 | 153.5 | Moderate |
V1 | 127 | Moderate |
V2 | 78.5 | Minor |
ER1 | 122 | Moderate |
Hazard | Measure Taken to Reduce the Risk |
---|---|
M1 | Needle deflection is almost impossible to avoid but must be kept under certain limits. This is the main reason why the expected accuracy (~2.5 mm) is rather poor within these applications. This hazard is strongly related to the procedure control flow and the only way to avoid the negative effects of deflection is to carefully monitor the needle trajectory between two consecutive scans and decide if it still fits the required outcome in terms of final position within the tumor (if the radiation time or intensity can be adjusted accordingly) or if it hits vital tissue (e.g., important blood vessels), case in which it has to be removed and the trajectory adjusted. |
M2 | Proximity sensors have been mounted on the MNID and the stroke of each axis is strictly monitored. The torques within the KUKA iiwa are also be monitored. Joint velocities are limited when the MNID approaches the patient. |
M3 | Since KUKA iiwa is a collaborative robot, the torques are strictly monitored. Limit the ranges of motion of each axis and use proximity sensors. |
M4 | An additional motion axis has been installed and programmed to use the signal of a distance sensor measuring the real-time displacement of the CT couch within the CT bore. |
M5 | The needle rack has been designed to firmly hold up to 6 needles using elastic elements. The needle locations are numbered and sufficiently spaced. An artificial ventilation system will be used to strictly monitor the patient’s breathing, which allows the implementation of the motion gating strategy. |
M6 | The gripper has been custom designed to grip the needles using a large area. Stroke limiters have been installed. |
E1 | Low voltage components have been used and the proper regulated protection of the system has been installed. |
E2 | A strict protocol has been developed, in which all functions of the robotic system are tested within the initialization phase. Signal monitoring is strictly monitored. Proper regulated protection has been used. |
E3 | Use proper regulated protection for the system. |
T1 | Avoid using parts that would create heat in contact with the patient. Avoid unnecessary contact with the patient in general. |
I1 | CT scanning implies irradiation with X-rays. The focus here is to avoid unnecessary irradiation (e.g., fewer CT scans) and the strict delimitation of the CT scan range. Nevertheless, irradiation within this kind of procedure cannot be avoided. |
V1 | Avoid resonance. Check for loose parts. |
V2 | Check for loose parts. Use low friction materials (e.g., stainless steel screw with brass nut). |
ER1 | Firmly hold the patient in the right position on the CT couch. Constantly check the tumor position. |
Code | Function | Potential Failure Mode | Potential Failure Effect | Potential Cause | Recommended Actions |
---|---|---|---|---|---|
F1 | Needle gripping | Wrong needle is gripped | The insertion order may be disrupted. Other needles may fall from the rack | Wrong numbering, rack position changed, needle missing from the rack | Before starting the procedure check that all needles are in place, in the correct order. |
F2 | Needle gripping | Inaccurate positioning | The needle does not reach the target point | The needle may move inside the gripper during insertion | Design the gripper to firmly grip the needles using specific dimension grooves. |
F3 | Needle positioning | Reach the end of motion range | The needle does not reach the target point | Not enough stroke Lack of stroke limiters | Design properly the stroke lengths. Install stroke limiters |
F4 | Needle positioning | Inaccurate positioning | The needle does not reach the target point | Play within the screw-nut mechanism | Use preloaded nuts. Check them after each 5 procedures |
F5 | Needle insertion | Inaccurate positioning | The needle does not reach the target point | Needle slips inside the gripper | Design the gripper to block the slipping tendency |
F6 | Needle insertion | Patient’s liver hemorrhage | Unexpected blood loss | Needle deflects from the imposed trajectory | Install force sensor to detect out of range insertion forces. |
F7 | Needle insertion | Inaccurate positioning | Unexpected blood loss. The needle does not reach the target point | Current needle collides with previous inserted needles | Design the gripper to avoid accidental collisions. Use parallel trajectories. Insert first needle in “the middle of the tumor” |
F8 | Needle insertion | Inaccurate positioning | The needle reaches the tumor, but not the imposed target point | Needle deflects from the imposed trajectory | Choose one of the following: remove and reinsert needle; recalculate the other needles trajectories; recalculate dosimetry |
F9 | Needle retraction | Inaccurate positioning | After insertion, the needles move from the targeted lesion | The gripper collides with the previous inserted needles | Design the gripper jaws in a slight conical form. Install stroke limiters to control the gripper opening |
RPN Value | Failure Risk Linguistic Variable |
---|---|
0–200 | Low |
100–600 | Moderate |
500–900 | High |
800–1000 | Very High |
Failure Mode | Severity | Occurrence | Detection | RPN Value |
---|---|---|---|---|
F1 | 6.3 | 3.1 | 6.2 | 648 |
F2 | 8.1 | 6.4 | 8.1 | 503 |
F3 | 3.2 | 5.5 | 8.4 | 305 |
F4 | 7.1 | 5.7 | 4.7 | 739 |
F5 | 7.9 | 7.2 | 6.4 | 669 |
F6 | 9.8 | 5.8 | 4.3 | 763 |
F7 | 9.1 | 7.9 | 7.5 | 578 |
F8 | 6.2 | 9.1 | 8.3 | 419 |
F9 | 8.4 | 6.9 | 6.6 | 674 |
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Gherman, B.; Hajjar, N.A.; Tucan, P.; Radu, C.; Vaida, C.; Mois, E.; Burz, A.; Pisla, D. Risk Assessment-Oriented Design of a Needle Insertion Robotic System for Non-Resectable Liver Tumors. Healthcare 2022, 10, 389. https://doi.org/10.3390/healthcare10020389
Gherman B, Hajjar NA, Tucan P, Radu C, Vaida C, Mois E, Burz A, Pisla D. Risk Assessment-Oriented Design of a Needle Insertion Robotic System for Non-Resectable Liver Tumors. Healthcare. 2022; 10(2):389. https://doi.org/10.3390/healthcare10020389
Chicago/Turabian StyleGherman, Bogdan, Nadim Al Hajjar, Paul Tucan, Corina Radu, Calin Vaida, Emil Mois, Alin Burz, and Doina Pisla. 2022. "Risk Assessment-Oriented Design of a Needle Insertion Robotic System for Non-Resectable Liver Tumors" Healthcare 10, no. 2: 389. https://doi.org/10.3390/healthcare10020389
APA StyleGherman, B., Hajjar, N. A., Tucan, P., Radu, C., Vaida, C., Mois, E., Burz, A., & Pisla, D. (2022). Risk Assessment-Oriented Design of a Needle Insertion Robotic System for Non-Resectable Liver Tumors. Healthcare, 10(2), 389. https://doi.org/10.3390/healthcare10020389